Blind Spot Management During Loading/Unloading Operations
The Problem
Blind spots are one of the leading safety risks during loading and unloading operations. These are areas around vehicles and equipment where operators cannot see, increasing the chance of collisions, incidents, or injuries. Poor ground stability, unclear communication, and failing to enforce safety zones often contribute to these events. Today, we’ll identify these hazards and discuss the solutions to manage blind spots effectively, ensuring a safer working environment for everyone.
Identify the Hazards
- Blind Spots: Operators cannot see ground personnel or objects near plant and equipment.
- Ground Instability: Uneven, soft, or unprepared ground can cause machinery to shift or tip.
- Improper Stabiliser Deployment: Partially deployed stabilisers increase the risk of tipping.
- Overloading: Exceeding rated lifting capacity can cause equipment failure.
- Poor Communication: Miscommunication between operators and spotters can result in unsafe movements.
- Adverse Weather: Rain, wind, or low visibility increases operational risks.
Safety Practices and Preventative Measures
Ground Preparation:
- Assess ground conditions before setting up plant.
- Ensure ground is firm, level, and capable of supporting the load.
- Use crane mats or steel plates as necessary.
- Identify and manage underground services before starting.
Proper Stabiliser Deployment:
- Always fully deploy stabilisers and use appropriate pads or blocking.
- Inspect stabiliser components regularly for wear or damage.
- Monitor stabiliser pressure during use.
Load Chart Compliance:
- Refer to manufacturer load charts and stay within safe working limits.
- Factor in rigging gear and dynamic loads.
- Account for radius, boom angle, and wind conditions when planning a lift.
Spotter Duties:
- Maintain constant visual or radio contact with the operator.
- Use standardised hand signals or pre-agreed communication.
- Stand in safe, visible positions for both operator and load.
- Stop operations immediately if conditions become unsafe.
Exclusion Zones:
- Mark zones with barriers, cones, or hazard tape.
- Include swing radius, lifting path, and overhead risks.
- Keep unauthorised personnel out of operating areas.
Weather Considerations:
- Monitor for wind, rain, or visibility issues that could impact safety.
- Pause or alter operations when weather becomes unsafe.
- Have emergency shutdown procedures ready.
Real-Life Case or Scenario
A spotter entered a crane’s blind spot during lifting operations. Due to poor communication and line-of-sight issues, the operator didn’t see the spotter, leading to a near miss. Fortunately, the worker only received minor injuries. This could have been prevented by enforcing exclusion zones and improving communication.
Employee Responsibilities
- Inspect equipment and ground before commencing work.
- Use agreed signals and maintain communication.
- Stay out of exclusion zones and be aware of blind spots.
- Report unsafe conditions straight away.
Employer Responsibilities
- Provide safe and well-maintained machinery.
- Ensure signal persons and operators are trained in blind spot management.
- Clearly mark exclusion zones and enforce access rules.
- Monitor weather and adjust operations as needed.
Discussion & Questions
- “Has anyone experienced a near miss involving blind spots on site?”
- “What more can we do to manage blind spots effectively here?”
- “How can we improve communication between operators and spotters?”
Encourage team members to share insights and safety solutions.
Commitment/Action Plan
Let’s commit to being blind spot aware and communicating clearly. Before work begins, check the stability of the ground, deploy stabilisers correctly, and confirm that exclusion zones are established and visible.
Wrap-Up
Managing blind spots is a shared responsibility. With awareness, clear communication, and effective controls, we can reduce risks and protect our team. Thank you for staying alert and making safety a top priority.
Standards Overview
- WorkSafe NZ requires all plant and lifting operations to be managed according to the Health and Safety at Work Act (HSWA).
- Plant must be inspected and maintained before use.
- Signal persons must be trained and competent.
- Exclusion zones must be enforced to protect workers.
- Weather conditions must be factored into operational planning.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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